We, Saphire Polymers, manufacture FRP / GRP fiberglass products by using wet lay up process with match die moulding for double side finish, single side smooth contact moulding and PP/PVC lined with FRP / GRP moulding. We use following procedure for manufacturing products-

• Gel coat made from aerosil/talk powder, chalk powder mixed with liquid thermosetting plastic called resin is applied on the mould depending upon the individual requirements of the products constituting up to 0.3mm thick of the product.


• A layer of CSM (chopped strand matt) is laid on the dried gel coat and wetting of the same is done using resin.


• Subsequent layer of Owen roving or CSM is laid with procedure to build up the thickness of desired level.


• In case of match die moulding the moulds are matched and excess resin squeezed with fasteners to lock the moulds.
  

The products manufactured by us have advantages like they are chemically inert to many of the chemicals, low cost of manufacture in case of low volumes, cost per mould constitutes only making a wooden pattern and maximum of two piece charges, intricate designs can be made without welding or bonding and density between 1.42 to 2 resulting in high strength to weight ratio. There are some limitations also which should be kept in mind like low shelf life of raw material, high labor component as each and individual piece has to be made separately without the use of machines.
 

RP (Fiber-reinforced plastics) and GRP (Glass-reinforced plastic) enclosures have been used for several decades in various sectors and industries. The FRP enclosures manufactured by us provide long lasting services and contains numerous benefits like lower thermal expansion, ability to fabricate multi directional mechanical properties, excellent fatigue time and fracture resistance, simplification of manufacturing by having the whole unit as a one piece without joints or welds, lower tooling cost alternative, high specific strength properties (20-40% weight savings) and outstanding corrosion resistance. GRP (Glass-reinforced plastic) is a composite material or fiber-reinforced plastic made of silicone based glass fabric having very thin strands and laminated using Polyester based resin (thermo setting plastic) which when cured will result in very high mechanical. It has advantages like corrosion-free, strength that almost matches metals (non-reinforced plastic material has approx. 100 times less stability) and by increasing wall thickness and optimum fiber alignment the enclosure can be made with extra reinforcing at the edges. Besides all this FRP and GRP enclosures, our products are used for aircraft drop electronic guidance boxes, electrical panels, generator cabinets for controlling noise pollution, etc.

We manufacture FRP/GRP pipes and fitting that are made in various dimensions and shapes, fulfilling the need of various industries and purposes. The pipes and fitting manufactured by us can bear heat and high temperature and has the resistant power against chemical reactions like acid, alkali or salt. We manufacture and supply the FRP/GRP pipes and fitting whose friction correlation is low and its surface is not only smooth but it is clean and clear. The best part of these pipes and fitting is that they are inert to various acids and chemicals and it can last for long time. There are various benefits in FRP/GRP pipes and fitting manufactured by us like:

• construction without joints or welds.
• Non-corrosive and immune to galvanic or electrolyte erosion.
• UV resistant.
• Chemically inert to almost all kinds of chemicals within specific temperature.
• Used for transporting CLO2, Brine solution, H2SO4, NO2, Phosphoric acid, etc.
• Lightweight.
• Cost effective with assured quality.
• Excellent flow properties.
• Smooth inner surface.
• Nonflammable.

Cross Section of Pipe (Economy) Variety

• Inner Surface: The interior surface 0.25mm-0.5mm is a smooth resin rich gel coat made of Resin mixed with chemically inert aerosil producing a smooth surface for increasing the flow.
• Next Interior Layer: Laminate reinforced with 450 CSM glass fabric of two layers. Providing optimum corrosion-resistance when combined with the suitable resin for the specific chemical conditions.
• Remaining Thickness: Subsequent reinforcing layers of woven roving-chopped strand mat along with mild reacting resins are used to build the pipe to the desired wall thickness.
• Exterior Surface: The final chemically inert layer provides protection against weathering, fumes spillage and ultraviolet attack. This gives the pipe a longer life and reduces maintenance expenses.
  • Inner Surface: The interior surface 0.25mm-0.5mm is a smooth resin rich gel coat made of resin mixed with chemically inert aerosil producing a smooth surface for increasing the flow.
  • Next Interior Layer: Laminate reinforced with 450 CSM glass fabric of two layers. Providing optimum corrosion-resistance when combined with the suitable resin for the specific chemical conditions.
  • Remaining Thickness: Same as above.
  • Exterior Surface: The final chemically inert layer provides protection against weathering, fumes spillage and ultraviolet attack. This gives the pipe a longer life and reduces maintenance expenses. 
    

Cross Section Of Pipe (Premium) Variety

FRP/GRP tanks are used for numerous industries and sectors. The FRP/GRP tanks manufactured by us contain high quality of material for storing acids, water, alkalis and other liquid items. These tanks contain thick base for ensuring proper storage of the items. The tanks are available in various sizes and are immune to strong acids and alkalies as these are used for storing ferrous sulphate; dilute H2SO4, acetic acid, gasoline, hydrogen peroxide, chromic acid, phosphoric acid, chlorine, ammonium hydroxide, nitric acid, brine, etc. The FRP/GRP tanks manufactured and supplied by us have features like chemical resistant interior and exterior, easy in maintaining, protection against industrial fumes and extreme weather conditions, light in weight and easy in modification, modest in initial cost.
We manufacture FRP/GRP tanks that can resist various acids and chemical at temperatures of –40deg C to 160 deg C and make them in proper shape and size to preserve the items. These tanks are manufactured according to customers’ requirement for shape and size using Destructive pattern method.

Method of Construction:

Pattern:

• Nu wood or hard board pattern is constructed for the size and dimensions specified.
• Smooth putty finishing from outside is made on the pattern (the final equipment will have smooth internal finish).
• All flanges and other manholes are fixed using the above material and finished for smooth external surface (internal in piece).
• Dimensions for pattern are the internal dimensions for the final equipment.
• Polyvinyl alcohol coating and wax polish for the pattern to applied at the final stage for giving luster and release of the pattern.
  

MOC for Tanks:

• Gel coat made from chemically inert Aerosil and resin.
• Two Gel coats are applied in order to secure from any kind of porosity.
• Isopthalic Resin which have a viscosity of min 550cps and specific acid value are used .
• CSM (chopped strand matt) 450 +/- 20 grams is used for each layer for thickness to the desired level.
• Final layer is of surface matt to give a comparatively lesser rough external surface.
• Gel coat is applied / resin coating is given on the final surface..
• No filler is used of any kind.
  

Manhole / Pipes / Inserts

• Manhole is about careful construction.
• Pipes and fittings are moulded with FRP (bonded with the main system).
• Flanges and other external surfaces are moulded without any joint or welding.
  

We manufacture FRP-GRP motor guards with chemical resistant materials so that they can be used by any industry. FRP-GRP motor guards manufactured and supplied by us protects the element from high voltage, phase reversal, protects from loss of the power and avoid nuisance tripping. These motor guards are the safest and the most economical to be used to protect the electrical appliances from any kind of over heating or power breakage. It is the motor guard that protects the electric appliances from the fluctuations of the power and any sort of consequential damage. There are numerous advantages of FRP-GRP motor guards manufactured by us:

• Electrical insulation of Class F.
• Thermal insulation against high temp.
• Prevention against electrical shock.
• Fire retardant characteristics (Optional).
• Larger Lifetime of motor guards.
• Budget friendly cost.
• Prevents the intrusion of materials like paper wipe, impurities, dust, etc.
  

We are the manufacturer and supplier of FRP/GRP material handling equipments. We manufacture FRP/GRP material handling equipments on contours design and specification of the customer requirements. These are mainly used for acedic/alkaline environment, suitable for heavy payloads that includes PARADROP. FRP/GRP material handling equipments manufactured by us are used for industrial material handling purpose. These are manufactured according to client’s specification and design for individual requirements. Our products are additionally and intervally reinforced with MS/PUF/SS/FRP or any other material.